INSTALLATION MANUAL © 2011 Aqua-Hot Heating Systems Inc. CAUTION: The Aqua-Hot tank and heating loop operate at 0.0 psi (zero pressure system). Air pressure applied to the tank MUST NOT exceed 20 psi. Excess pressure will result in internal damage. CAUTION: Before welding or plasma cutting on any coach; it is necessary to disconnect the electric wiring to the Aqua-Hot System. Failure to disconnect the wires from the Aqua-Hot System before using a welder or a plasma cutter on the coach may cause damage to the Aqua-Hot. TABLE OF CONTENTS Aqua-Hot 375-D Installation Manual Introduction ........................................................................................................................................... 5 Section 1: Aqua-Hot Hydronic Heating System Technical Information .......................................................................................................................... 6 Section 2: Aqua-Hot Installation Installing the Mounting Tray and the Aqua-Hot .............................................................................. 10 Overall Aqua-Hot Dimensions ........................................................................................................... 12 Installing the Cable-Clamp Fittings .................................................................................................... 14 Installing the Wires into the Terminal Blocks .................................................................................. 14 Installing the Expansion Tank ............................................................................................................ 15 Section 3: Hydronic Heating System Heat Exchanger Location and Clearances ......................................................................................... 16 Heat Exchanger Mounting Requirements ......................................................................................... 16 Mounting the Heat Exchangers .......................................................................................................... 17 Sample Heating System Floorplan ...................................................................................................... 19 Wiring the Heat Exchangers ............................................................................................................... 20 Plumbing Requirements ....................................................................................................................... 22 Plumbing the Hydronic Heating System ........................................................................................... 23 Section 4: Thermostats Fresh Water Tank Thermostat ............................................................................................................ 26 Room Thermostats ............................................................................................................................... 27 Section 5: Domestic Water System Domestic Water System Requirements ............................................................................................. 28 Domestic Water System Plumbing ..................................................................................................... 28 Section 6: Switch Panel Switch Panel Location .......................................................................................................................... 30 Switch Panel Mounting ........................................................................................................................ 30 Switch Panel Wiring .............................................................................................................................. 30 Section 7: Fuel System Fuel Filter Location .............................................................................................................................. 32 Fuel System Requirements ................................................................................................................... 32 Fuel System Installation © 2011 Aqua-Hot® 375-D Installation Manual TABLE OF CONTENTS (CONTINUED) Section 8: Exhaust System Exhaust System Requirements ............................................................................................................ 35 Installing the Exhaust System ............................................................................................................. 35 Section 9: Power Source Wiring Connecting the 12 Volt-DC Power .................................................................................................... 39 Connecting the 120 Volt-AC Power .................................................................................................. 39 Installing the Wires into the Terminal Blocks .................................................................................. 39 Section 10: Purging the Systems Purging the Hydronic Heating System ............................................................................................... 41 Purging the System by Grounding the Zone Thermostat Connection ......................................... 42 Purging the Domestic Water System.................................................................................................. 43 Section 11: Initial Start-Up Activating the Aqua-Hot ...................................................................................................................... 46 Appendices: Appendix A: Wiring Diagram ............................................................................................................. 47 Appendix B: Wire Gauge Information .............................................................................................. 48 Appendix C: Antifreeze Types ............................................................................................................ 49 Appendix D: Antifreeze Mixture Water Quality Recommendations ............................................ 49 Appendix E: Antifreeze Terms and Mixture Ratio .......................................................................... 50 Appendix F: Measuring Propylene Glycol Using a Refractometer .............................................. 52 INTRODUCTION The Aqua-Hot 375D is a hydronic (water based) heating sys- Danger, Warning, Caution, and Note Boxes: tem, and a tank-less hot water system. Danger, Warning, Caution, and Note boxes appear through- The heating system provides moist, quiet, comfortable, inte- rior heat with up to three separate, thermostatically- out this manual as a means of alerting the installer to impor- controlled temperature zones, and prevents tank and line tant information. freezing in the bays. The tank-less hot water system produces 90 gallons per hour of continuous, on-demand hot water. ʆDANGER ʆ This TribridHot™ designated system uses one or a combina- INDICATES THAT PERSONAL INJURY IS LIKELY OR IMMI- tion of heat sources to heat FDA-approved Generally Recog- NENT. nized as Safe (GRAS) propylene glycol based antifreeze solution in the Aqua-Hot’s boiler tank. The 375D features a 120 Volt-AC, 1500 Watt electric element, and a 12 Volt-DC WARNING! powered diesel burner. Indicates that serious damage to the heater will occur and When AC power is available, plug in. When dry camping, personal injury is possible as well. use the diesel fuel source. The electric power and diesel fuel sources can be used separately or together. CAUTION Indicates that damage to the heater is possible. NOTE: Indicates information that requires special attention by the installer. New Low Emissions Technology virtually eliminates smoke and smell from the exhaust by reducing total hydrocarbon emission by 82% making Aqua-Hot the cleanest burning diesel powered hydronic system available. This Installation Manual is designed to aid in the installation process of the Aqua-Hot 375-D Hydronic Heating System by a trained and experienced technician. Please note that all Danger, Warning, Caution, and Note boxes, appearing as needed throughout this manual, must be reviewed and adhered to during the installation procedure in order to avoid potential hazards, which could result in injury, death, product damage, or property damage. Should additional assistance be needed, please contact Aqua-Hot Heating Systems at 1-800-685-4298, Monday through Friday, between the hours of 7:00 AM and 4:00 PM Mountain Standard Time. — Page 5 — © 2011 Aqua-Hot® 375-D Installation Manual SECTION 1: AQUA-HOT HYDRONIC HEATING SYSTEM Figure 1 Diesel Burner, Heat Input (Firing Rate) ................................................................................................................................. 59,000 BTU/hr Diesel Burner, Fuel Consumption (Continuous Operation) ........................................................................................................ 0.40 gal/hr Heater, Voltage/Maximum Power Consumption ................................................................................................... 12 Volt-DC/245 watts Electric Heating Element specifications ................................................................................................................. 120 Volt-AC/1500 watts Zone Heat Circulation Pump specifications ................................................................................................. (2) 12 Volt-DC/21 watts each Number of Heating Zones .......................................................................................................... Maximum of 2, plus Bay Heat Exchanger Domestic Water Heating Capacity .......................................................................................................................